Mercruiser Control Box Removal

Bubbakat / BobPaul, seeing as how I am so good as asking questions, my friend FuzzFace needs information on how to remove the Mercruiser control box from the boat. He has a problem where no hot wire is running to the ignition, but has traced wires back to the control box. So, it has to come out for a look-see. It also will not go into forward. Reverse is Okay, but no forward....moves about 2" then stops. We found one set screw behind the handle but cannot get the handle off. We believe once we get the handle off there will be a nut or nuts holding the control box on, but we are stuck. Got any ideas?

Has he checked the circuit breaker at the engine? Got an OMC Cobra drive in the other day with the same problem. It was a blown 50 amp fuse. Mercruisers have 50 amp breakers.

I'll look into the control box removal today. I do know it's a difficult process in stern drive boats.

As much as I don't like to mention it, I replaced a cable last week in one of those Mercruiser's, along with a gimball bearing and drive shaft seal. Always agrivates me that anyone made those things, but it really pays good.

The attachment shows the problem. We have removed one set screw from the side of the handle, and the button in the middle used to release the handle from its neutral position. Everything we have seen says this handle is just set on a splined shaft and should pull apart. It don't. Have we forgot something or should we just use brute force to remove it?

Attached Files:

That handle is setting on a spline that is most likely oxidized. Either get some pb blaster in it or just use a small puller and brute force. Do you remember the old door handles on the old model Chevy's. Well this is the same principle but with out the circular clip. It is just stuck on it. if you have removed the screw from the side and the center button.

As usual, your diagnosis was right on. We put some of that fishbait stuff, you know - WD40, on the splines, moved the handle a little, and Viola, the darn thing just popped off. How do you guys do it all the time...can't you be wrong once in a while so us normal people won't feel so stupid.

As usual, your diagnosis was right on. We put some of that fishbait stuff, you know - WD40, on the splines, moved the handle a little, and Viola, the darn thing just popped off. How do you guys do it all the time...can't you be wrong once in a while so us normal people won't feel so stupid.